Welcome, Guest.
Register Donate Calendar Search Today's Posts Mark Forums Read

Welcome to the Offroad Passport Community Forum!

This is a community for planning and discussing offroad adventures. All makes and models of offroad vehicles are welcome! Multi-day expedition-style trips are our main focus, but there are plenty of day runs, clinics, and tech-days as well.

The forum is free for Basic Membership! Optional Premium Membership includes such perks as exclusive professionally organized trips and events. Please note that you may view the forum as a guest, but will need to register in order to post or to access certain areas of the site.

Note: If you are already a registered member, please login to remove this message.

Reply
View Thread
 
Thread Tools Display Modes
  #1  
Old 12-29-2009
Number7's Avatar
Number7 Number7 is offline
(George)
Co-Founder
 
Join Date: Jul 2009
Location: Fountain Hills, AZ
Vehicle: Number 7
Posts: 2,384
Reputation: Number7 is on a distinguished road
Default TJS Trail Welder
I built this trail welder. This is made with readily available stuff, each unit can be built for around $120. It's an arc welder to be used with 2 batteries, but could be used with 1 battery in a pinch (but it would be 12v. vs. 24v.).


We'll have this on all our runs from now on.

George
__________________
George & Diane
'00 TJ 2.5L LowOutput w/5 spd.
4" Teraflex Longarm w/ 33" MT's
4:88 Gears / Super 35 Rear
Dana 30 Front w/ Warn Hubs
TeraLow 4:1 T-Case
OX Lockers


Every Dog Has His Day!
Reply With Quote
  #2  
Old 12-29-2009
K7VZ K7VZ is offline
(Virgil) (K7VZ)
Basic Member
 
Join Date: Aug 2009
Location: PHX, AZ
Vehicle: 2014 Ram
Posts: 508
Reputation: K7VZ will become famous soon enough
Default Re: TJS Trail Welder
Nice. Will there be a more detailed write-up? What cost so much? It just seems you could do that cheaper than $120.
Reply With Quote
  #3  
Old 12-29-2009
dzJeepChic's Avatar
dzJeepChic dzJeepChic is offline
(Diane) (KD7JPC)
Co-Founder
 
Join Date: Jul 2009
Location: Fountain Hills, AZ
Vehicle: '92 XJ
Posts: 8,293
Reputation: dzJeepChic is on a distinguished road
Default Re: TJS Trail Welder
Originally Posted by K7AZV View Post
Nice. Will there be a more detailed write-up? What cost so much? It just seems you could do that cheaper than $120.
Virgil, George says the cable is the high dollar item here. It's really thick and the price of it varies; he said he might have estimated too high; he had it around the house and doesn't know how much it costs right now.

The other stuff (vice grips, lead battery connectors, arc rod holder and some soldering supplies) he estimates around $25.00 - $35.00 About 12' of cable he estimated at $90.00.

This kit is going into theksmith's WJ, but he's building another set to go in our rigs. He said he'd do a more detailed write-up when he makes that one.

d
__________________
My '92 XJ Clifford
Reply With Quote
  #4  
Old 12-29-2009
K7VZ K7VZ is offline
(Virgil) (K7VZ)
Basic Member
 
Join Date: Aug 2009
Location: PHX, AZ
Vehicle: 2014 Ram
Posts: 508
Reputation: K7VZ will become famous soon enough
Default Re: TJS Trail Welder
Thanks. That makes sense. Heavy guage wire isn't cheap. I always thought about making something like that out of jumper cables, but never thought of actually putting a rod holder on the end.
Reply With Quote
  #5  
Old 12-29-2009
CampnFever's Avatar
CampnFever CampnFever is offline
Basic Member
 
Join Date: Nov 2009
Location: A Hop,Skip and A Jump from the Sierra's
Vehicle: 1993 Jeep Cherokee Sport
Posts: 64
Reputation: CampnFever is an unknown quantity at this point
Default Re: TJS Trail Welder
Originally Posted by K7AZV View Post
Nice. Will there be a more detailed write-up? What cost so much? It just seems you could do that cheaper than $120.
better yet, will he be willing to make and ship (cost permitting) some for those of us who don't have the means to make our own ?

I like how they are compact and take up minimal space to store.
__________________
Credo Quia Absurdum
Reply With Quote
  #6  
Old 12-30-2009
Number7's Avatar
Number7 Number7 is offline
(George)
Co-Founder
 
Join Date: Jul 2009
Location: Fountain Hills, AZ
Vehicle: Number 7
Posts: 2,384
Reputation: Number7 is on a distinguished road
Default Re: TJS Trail Welder
Originally Posted by CampnFever View Post
better yet, will he be willing to make and ship (cost permitting) some for those of us who don't have the means to make our own ?

I like how they are compact and take up minimal space to store.

I'm going to do some testing with this setup to make sure it works good. If it passes my test I will build some more welders and get the price nailed down. Please stand by. George
__________________
George & Diane
'00 TJ 2.5L LowOutput w/5 spd.
4" Teraflex Longarm w/ 33" MT's
4:88 Gears / Super 35 Rear
Dana 30 Front w/ Warn Hubs
TeraLow 4:1 T-Case
OX Lockers


Every Dog Has His Day!
Reply With Quote
  #7  
Old 12-30-2009
macinyart's Avatar
macinyart macinyart is offline
(KC9PKI)
Basic Member
 
Join Date: Aug 2009
Location: Fountain Hills, AZ
Vehicle: 1994 YJ
Posts: 199
Reputation: macinyart is an unknown quantity at this point
Default welder
I would buy one of these if I knew how to weld. I have a small welder, 110V. My welds are about three degrees below "farmer weld" ( not repairable with a grinder) and, in addition, I set my shoes on fire. It was interesting.
Reply With Quote
  #8  
Old 12-30-2009
mbuckner's Avatar
mbuckner mbuckner is offline
(Mike) (KE7GRM)
Premium Club Member
 
Join Date: Aug 2009
Location: Cloudbreak, Arizona
Vehicle: 2001 TJ
Posts: 750
Reputation: mbuckner is on a distinguished road
Default Re: TJS Trail Welder
Good morning George,

Are you going to have a demo class on how to use this welding system?

Eye protection?

Best regards,

Mike
Reply With Quote
  #9  
Old 12-30-2009
CampnFever's Avatar
CampnFever CampnFever is offline
Basic Member
 
Join Date: Nov 2009
Location: A Hop,Skip and A Jump from the Sierra's
Vehicle: 1993 Jeep Cherokee Sport
Posts: 64
Reputation: CampnFever is an unknown quantity at this point
Default Re: TJS Trail Welder
Originally Posted by Number7 View Post
I'm going to do some testing with this setup to make sure it works good. If it passes my test I will build some more welders and get the price nailed down. Please stand by. George

Standing by..
__________________
Credo Quia Absurdum
Reply With Quote
  #10  
Old 01-20-2010
Number7's Avatar
Number7 Number7 is offline
(George)
Co-Founder
 
Join Date: Jul 2009
Location: Fountain Hills, AZ
Vehicle: Number 7
Posts: 2,384
Reputation: Number7 is on a distinguished road
Default Re: TJS Trail Welder
I got around to making 2 more trail welders today and I tried them out. Here they are:



One I'm keeping for myself, this one is for sale for $93.00 (that's my cost) cash & carry, shipping extra based on your zip code:




Here's a little demo.

1. Trail Welder hooked to 2 batteries:



Prepped a piece of thin-guage scrap metal with negative lead clamped on:



I used 6013 1/16" thick Campbell Hausfield welding rod:




As you can see, it burned hot & I should've gone a little faster:




Next I tested a thicker pipe, approx. 3/32" thick, with good results:







I also tried welding with a coat hanger, that sucked. I tried using #4 bailing wire, which it turns out could be done, but it splattered a lot. I also tried a thicker rod than the one I mentioned above, but it seemed to be too cold, it didn't melt very well (maybe with more batteries it would've been better). The rod I showed in the write-up worked the best, it's the one I recommend for use with the trail welder shown here.

The trail welder takes a little bit of getting used to. It wants to burn faster than my home welder. It's still a great tool to have on the trail, it could get you off the trail when a welder is needed. I noticed an additional benefit; these could be substituted for jumper cables in a pinch.

George

P.S. Campnfever has first dibs on the extra set shown here.
__________________
George & Diane
'00 TJ 2.5L LowOutput w/5 spd.
4" Teraflex Longarm w/ 33" MT's
4:88 Gears / Super 35 Rear
Dana 30 Front w/ Warn Hubs
TeraLow 4:1 T-Case
OX Lockers


Every Dog Has His Day!
Reply With Quote
Reply

Bookmarks

« Previous Thread | Next Thread »
Thread Tools
Display Modes


Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
   
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
   
Terms of Service

Similar Threads
Thread Thread Starter Forum Replies Last Post
"Ultimate" Trail Welder & Jumper Cable Kit theksmith All Other Activities, Gear & Resources 21 03-15-2017 08:00 AM
Possitive Message to Enthusiasts: A TRAIL CLOSED IS NEVER REOPENED? BRC LEGAL OPENS TRAIL 38 dzJeepChic Land Use & Environmental Concerns 0 02-02-2015 08:12 PM
welder cart theksmith All Other Activities, Gear & Resources 5 10-19-2013 10:40 PM
2011-10-06 Hole in the Rock Trail aka Mormon Trail, Utah theksmith Trip Reports & Photos 50 04-16-2012 05:17 PM
Lincoln Stick Welder dzJeepChic Classifieds: Parts & Equipment For Sale 2 08-14-2010 11:02 PM